Retaining element for a mechanical component

ABSTRACT

A retaining element which retains a mechanical element within the cavity of a body is described. Specifically, an electronically controlled valve and a motor housing retainer are described. The motor housing retainer comprises a printed circuit board, which may provide a connection to the motor.

CROSS-REFERENCE TO RELATED APPLICATIONS:

This patent application claims priority under 35 U.S.C. §119(e) from Provisional Patent Application No. 60/854,562, filed Oct. 25, 2006, the disclosure of which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

This invention relates generally to control systems and assemblies and, more specifically, relates to controllers and systems using electronically controlled valves, electronically controlled valves, and portions thereof, as well as to assemblies that include at least one valve.

BACKGROUND

Control systems for electronically controlled valves are used with many different types of fluids and gases for many different purposes. While control systems, their controllers, and the associated electronically controlled valves have many benefits, these control systems, controllers, electronically controlled valves and portions thereof may still be improved.

SUMMARY

An exemplary embodiment in accordance with this invention is a motor housing retainer that is a substrate composed of a dielectric material. The retaining element is configured to be affixed over a cavity in a valve body and prevents a motor housing from exiting the cavity in the valve body. Additionally the motor housing retainer provides one or more connection points for electrical connections.

In further exemplary embodiments, the motor housing retainer has an opening to allow access to the cavity. The motor housing retainer can be configured to fit within a recess on the valve body.

In additional exemplary embodiments, the motor housing retainer is a printed circuit board where at least two connectors are connected by a circuit on the printed circuit board.

In further exemplary embodiments, the motor housing retainer provides an electrical connection between the motor housing and the motor housing cover. The connection to the motor housing may be a Flexible Printed Circuit connector and uses a flat cable to connect to the voice coil. Such a connection may be used for coil current transfer.

Another exemplary embodiment in accordance with this invention is an electronically controlled valve. The valve includes a valve body with a cavity; a motor housing within the cavity; and a motor housing retainer. The retainer is a substrate composed of a dielectric material. The retaining element is configured to be affixed over a cavity in a valve body and prevents a motor housing from exiting the cavity in the valve body. Additionally the motor housing retainer provides one or more connection points for electrical connections.

In additional exemplary embodiments, the motor housing retainer has an opening to allow access to the cavity. The motor housing retainer can be configured to fit within a recess on the valve body.

In further exemplary embodiments, the motor housing retainer is a printed circuit board where at least two connectors are connected by a circuit on the printed circuit board.

In additional exemplary embodiments, the motor housing retainer provides an electrical connection between a voice coil, part of a coil header assembly, and a motor housing cover. The connection to the motor housing may be a Flexible Printed Circuit connector and uses a flat cable to connect to the voice coil. Such a connection may be used for coil current transfer.

A further exemplary embodiment in accordance with this invention is a valve retaining element. The element provides a means for preventing a motor housing from exiting a cavity in a valve body; and means for providing one or more electronic connections enabling coil current transfer.

In further exemplary embodiments, the valve retaining element provides an electrical connection between a voice coil, part of a coil header assembly, and a motor housing cover.

Another exemplary embodiment in accordance with this invention is a method which includes providing a valve body; inserting a spool actuator through an opening into a cavity within the valve body; and affixing a printed circuit board over the opening. The printed circuit board provides an electrical connection to the spool actuator and also mechanically preventing the spool actuator from passing through the opening.

BRIEF DESCRIPTION OF THE DRAWINGS

The attached Drawing Figures include the following:

FIG. 1 is a block diagram of a system including a portion for controlling an electronically controlled valve and the electronically controlled valve;

FIG. 2 is a cutaway, perspective view of an exemplary pneumatic valve;

FIG. 3 is a top perspective view of the valve shown in FIG. 2, without the electronics cover and the motor housing retainer;

FIG. 4 is a top perspective view of the valve shown in FIG. 2, without the electronics cover but with the motor housing retainer;

FIG. 5 is a top perspective view of the valve shown in FIG. 2, with the electronics cover (which covers the motor housing retainer);

FIG. 6 is a close-up top perspective view of the valve shown in FIG. 2, without the electronics cover but with the motor housing retainer;

FIG. 7 is a top view of screening for the motor housing retainer;

FIG. 8 is another close-up top perspective view of the valve shown in FIG. 2, without the electronics cover but with the motor housing retainer; and

FIG. 9 is a view of the motor housing retainer coupled to the motor housing and also of the coil header assembly and spool.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring to FIG. 1, a block diagram is shown of an exemplary system 100 having a portion for controlling an electronically controlled valve 120. System 100 also includes in this example the electronically controlled valve 120. FIG. 1 is a simplistic, high-level view of the system 100 that includes a control input 105, an adder 110, a spool position controller 115, the electronically controlled valve 120, and a feedback sensor module 150 that takes an input from one or more feedback sensors (not shown) and that produces one or more feedback signals 151. A valve controller 160 includes the adder 110, the spool position controller 115, and the feedback sensor module 150. The electronically controlled valve 120 includes a spool actuator 125, such as a voice coil, a spool 130, a body 135, an input 140, and an output 145.

The electronically controlled valve 120 controls fluid (e.g., gas, water, oil) flow 141 through the electronically controlled valve 120 by operating the spool 130. The spool actuator 125 controls movement of the spool 130 based on one or more control signals 116 from the spool position controller 115. The spool position controller 115 modifies the one or more control signals 116 based on the one or more input signals 111, which include addition of the control input signal 105 and the one or more feedback signals 151. The feedback sensor module 150 can monitor the spool actuator 120 (e.g., current through the spool actuator), a sensor indicating the position of the spool 130, or sensors indicating any number of other valve attributes (e.g., pressure or flow rate of the fluid flow 141). Aspects of the present invention are related to a number of the elements shown in FIG. 1.

Turning to FIG. 2 in addition to FIG. 1, a cutaway, perspective view is shown of an exemplary and non-limiting embodiment of a pneumatic valve 200. The pneumatic valve 200 includes an electronics cover 205, a motor housing retainer 207, a motor housing 210, an upper cavity 215, a lower cavity 216, a coil header assembly 220, a spool 230, a sleeve 260, a lower spring 240, an upper spring 245, external ports 270, 271, 280, 281, and 282, circumferentially spaced internal ports 270 a, 271 a, 280 a, 281 a, and 282 a, and a valve body 290. Coil header assembly 220 includes a voice coil portion 222 having a voice coil 221 and an overlap portion that overlaps a portion of the spool 230 and connects the spool 230 to the coil header assembly 220. The spool actuator 125 of FIG. 1 includes, in the example of FIG. 2, motor housing 210, coil header assembly 220, upper spring 245, and lower spring 240. It is noted that a view of the motor housing 210 is also shown in FIG. 9 and that at least a portion of the motor housing 210 is magnetized in order to be responsive to the voice coil 221.

In this example, a top surface 211 of the motor housing 210 contacts a bottom surface 208 of motor housing retainer 207 and is held in place by the motor housing retainer 207. In accordance with the exemplary embodiments of this invention, the motor housing retainer 207 is a PCB (printed circuit board). The motor housing retainer 207 serves multiple purposes, as is disclosed in more detail below. It should be appreciated that the motor housing retainer may be attached using a number of techniques, including using hardware such as screws; and sliding or snapping into place.

The spool 230 includes in this example a passage 265. The passage 265 has a number of purposes, including equalizing pressure between the upper cavity 215 and the lower cavity 216. The spool 230 may also be manufactured without passage 265.

As described below, the electronics cover 205 may include a connector 206 used to couple a spool position controller 115 to the voice coil 221 on voice coil portion 222. The electronics cover 205 is one example of a cover used herein.

A description of exemplary operation of the valve 200 is included in U.S. Pat. No. 5,960,831, which is hereby incorporated by reference in its entirety. U.S. Pat. No. 5,960,831 describes, for instance, airflow through the external ports 270, 271, 280, 281, and 283 and the circumferentially spaced internal ports 270 a, 271 a, 280 a, 281 a, and 283 a. It is noted that the springs 240, 245 along with the coil header assembly 220, motor housing 210, and spool 230, are configured such that the spool 230 blocks the ports 281A when no power is applied to the voice coil 221. Other portions of pneumatic valve 200 are also described in U.S. Pat. No. 5,960,831.

In FIG. 2, it can be seen that the motor housing 210 in the pneumatic valve 200 has a compressive force applied by spring compression (e.g., by springs 240 and 245). This force can cause the motor housing 210 to eject from the valve cavity (e.g., upper cavity 215). The exemplary embodiments of this invention retain the motor housing without unnecessarily increasing envelope size, cost, weight, or by adding unnecessary parts to the assembly.

Other possible approaches to solving this problem of retaining the motor housing 2 10 may employ the use of an adhesive, such as epoxy, or the use of hardware to secure the motor housing 210 to the body 290, manufacturing a cover plate that is attached with hardware, or by using a pressing or other bonding operation. However, each of these approaches adds additional parts and/or manufacturing steps to the assembly as well as making disassembly/maintenance more difficult. Another approach may be to thread the motor housing 210 (e.g., and a matching inner surface of the upper cavity 215 in the valve body 290). However, this approach would add additional cost to the assembly.

The use of the exemplary embodiments of this invention avoid these and other problems by using a PCB to serve at least three purposes 1) as a mechanical element, 2) as a spring contact plate for coil current transfer, and 3) as a connector location. As shown in FIG. 2 (and FIGS. 4 and 6), the motor housing retainer 207 is a PCB that acts as a mechanical element, a spring contact plate for coil current transfer, and a connector location for other product variants. This is explained in more detail below.

It is noted that the example described below specifically concerns retaining a spring loaded voice coil motor in a pneumatic valve. However, the techniques shown below are also applicable to retaining any mechanical element having static or dynamic forces thereon, and the use of the exemplary embodiments of this invention is not limited to retaining a spring loaded voice coil motor in a pneumatic valve.

Referring to FIG. 3 in addition to FIG. 2, a top perspective view is shown of the valve in FIG. 2, without the electronics cover 205 and the motor housing retainer 207. The valve body 290 has a top surface 1320 and an opening 1310. The top surface 211 of the motor housing 210 is shown in the upper cavity 215. Note that because of the force of the springs 240 and 245, the motor housing 210 as shown in FIG. 3 will eject from the valve body 290.

In order to retain the motor housing 210 in the upper cavity 215 of the body 290, the motor housing retainer 207 is attached to the body 290, show here attached with screws 1330 a and 1330 b, such as shown in FIG. 4. FIG. 4 is a top perspective view of the valve of FIG. 2, without the electronics cover 205 but with the motor housing retainer 207 (shown as the PCB 207A). It is noted that these motor housing retainer 207 may also be used to hold the mechanical assembly together even if no springs are present (e.g., the motor must still be held in place).

FIG. 5 is a top perspective view of the valve shown in FIG. 2, with the electronics cover 205 (which covers the motor housing retainer 207). Note that the connector 206 would be coupled to, e.g., a valve controller 160 using a cable (not shown) carrying control signal(s) 116. The connector 206 will also be coupled to the motor housing retainer 207.

FIG. 6 is a close-up top perspective view of the valve shown in FIG. 2, without the electronics cover 205 but with the motor housing retainer 207, embodied as the PCB 207A. The opening 1310 is used to house a cable from the motor housing retainer 207 to the voice coil 221, as described in more detail below.

Turning to FIGS. 7 and 8, FIG. 7 is a top view of an exemplary screening for the PCB 207A, while FIG. 8 is another close-up top perspective view of the valve shown in FIG. 2, without the electronics cover 205 but with the motor housing retainer 207. It is noted that, if desired, the motor housing retainer 207 can be mounted into a recess formed in top surface 1230 of the valve body 290. However such a recess is optional.

The screening shown in FIG. 7 indicates locations for three different connectors. Reference 1710 indicates a route for a cable. Connector J3 is used to attach cable 1720 from the motor housing retainer 207 to the voice coil 221. In this exemplary embodiment, a Flexible Printed Circuit (FPC) connector J3 is used to match the FPC cable 1720. The FPC cable 1720 was chosen as a flat cable for superior assembly features and operation. Regular wire or other cables and connectors may also be used. The cable 1720 is routed through the opening 1310. Connector J2 is used to couple the motor housing retainer 207 to the connector 206. The connector J1 includes a number of pads which may be used to connect other product variants to the motor housing retainer 207.

It should be appreciated that the PCB 207A could also accommodate other components such as integrated circuits, resistors, capacitors, etc., as is known in the art. Such components may be passive or may transform a signal passing through the component.

FIG. 9 is a view of the motor housing retainer 207 coupled to the motor housing 210 and also of the coil header assembly 220 and spool 230. It can be seen that the motor housing retainer 207 is coupled to the voice coil 221 using the cable 1720.

In general, the PCB 207A could be fabricated from any suitable substrate material, such as one or more layers of a glass-epoxy. In general, the thickness of the PCB 207A is made sufficient to resist any force applied to it by the motor housing 210 without experiencing undue deformation or bending. Depending on whether the motor housing 210 is electrically conductive, it may be desirable in some embodiments to include a layer or sheet of a electric material between the top of the motor housing 210 and the bottom of the PCB 207A, to prevent the shorting of electrical signal line.

The foregoing description has provided by way of exemplary and non-limiting examples a full and informative description of the best techniques presently contemplated by the inventors for carrying out embodiments of the invention. However, various modifications and adaptations may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings and the appended claims. All such and similar modifications of the teachings of this invention will still fall within the scope of this invention.

Furthermore, some of the features of exemplary embodiments of this invention could be used to advantage without the corresponding use of other features. As such, the foregoing description should be considered as merely illustrative of the principles of embodiments of the present invention, and not in limitation thereof. 

1. A retaining element comprising: a substrate composed of a dielectric material configured to be affixed over a cavity in a body, where the affixed substrate prevents a mechanical element from exiting the cavity in the body and further where the affixed substrate provides one or more connection points for electrical connections.
 2. The retaining element in claim 1, where the body is a valve body.
 3. The retaining element in claim 1, where the mechanical element is a motor housing.
 4. The retaining element in claim 1, where the substrate has an opening to allow access to the cavity.
 5. The retaining element in claim 1, where the substrate is configured to fit within a recess on the valve body.
 6. The retaining element in claim 1, wherein the substrate is a printed circuit board where at least two connectors are connected via a circuit on the printed circuit board.
 7. The retaining element in claim 1, wherein a first connector is connected to the mechanical element and a second connector is connected to a cover and further where the first connector and the second connector are electrically connected.
 8. The retaining element in claim 7, where the first connector is a Flexible Printed Circuit connector and uses a flat cable to connect to a voice coil.
 9. The retaining element in claim 7, where the connection is used for coil current transfer.
 10. An electronically controlled valve comprising: a valve body; a cavity within the body; a motor housing within the cavity; and a motor housing retainer, where the retainer comprises a substrate composed of a dielectric material configured to be affixed over a cavity in a valve body, where the affixed substrate prevents a motor housing from exiting the cavity in the valve body and further where the affixed substrate provides one or more connection points for electrical connections.
 11. The electronically controlled valve in claim 10, where the substrate has an opening to allow access to the cavity.
 12. The electronically controlled valve in claim 10, where the substrate configured to fit within a recess on the valve body.
 13. The electronically controlled valve in claim 10, wherein the substrate is a printed circuit board where at least two connectors are connected via a circuit on the printed circuit board.
 14. The electronically controlled valve in claim 13, further comprising a coil header assembly, which includes a voice coil, wherein a first connector is connected to the voice coil and a second connector is connected to a motor housing cover and further where the first connector and the second connector are electrically connected.
 15. The electronically controlled valve in claim 14, where the first connector is a Flexible Printed Circuit connector and uses a flat cable to connect to the voice coil.
 16. The electronically controlled valve in claim 14, where the connection is used for coil current transfer.
 17. A retaining element comprising: means for preventing a mechanical element from exiting a cavity in a body; and means for providing one or more electronic connections enabling coil current transfer.
 18. The retaining element in claim 17, where the body is a valve body and the mechanical element is a motor housing.
 19. The retaining element in claim 17, where a first connection is used to connect to a voice coil and a second connection is used to connect to a connector on a cover and further where the first connector and the second connector are electrically connected.
 20. A method, comprising: providing a valve body; inserting a spool actuator through an opening into a cavity within the valve body; and affixing a printed circuit board over the opening, the printed circuit board providing an electrical connection to the spool actuator and also mechanically preventing the spool actuator from passing through the opening. 